CN113977043A - Embedded type centralized controller device of welding system of crawling robot - Google Patents

Embedded type centralized controller device of welding system of crawling robot Download PDF

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Publication number
CN113977043A
CN113977043A CN202111193318.2A CN202111193318A CN113977043A CN 113977043 A CN113977043 A CN 113977043A CN 202111193318 A CN202111193318 A CN 202111193318A CN 113977043 A CN113977043 A CN 113977043A
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welding
circuit
power supply
centralized controller
controller device
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CN113977043B (en
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曾敏
袁松
石永华
王卓然
胡子鑫
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South China University of Technology SCUT
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South China University of Technology SCUT
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
    • B23K9/133—Means for feeding electrodes, e.g. drums, rolls, motors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/12—Automatic feeding or moving of electrodes or work for spot or seam welding or cutting
    • B23K9/127—Means for tracking lines during arc welding or cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/24—Features related to electrodes
    • B23K9/28—Supporting devices for electrodes
    • B23K9/287—Supporting devices for electrode holders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/32—Accessories

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Arc Welding Control (AREA)

Abstract

The invention discloses an embedded type crawl robot welding system centralized controller device which is characterized by comprising a processor, and a conversion circuit, a power supply circuit, a storage circuit, an interface circuit, a communication circuit, a digital quantity input circuit and a digital quantity output circuit which are respectively connected with the processor. The embedded centralized controller device for the welding system of the crawling robot adopts heterogeneous multi-core chips, has high inter-core communication speed, strong anti-interference capability, small volume, low cost and rich expanded interfaces, and meets the requirement of cooperative control with multiple devices in the welding occasion of the crawling robot. Welding parameters can be adjusted in real time through the centralized controller device, the welding process is controlled, the working efficiency is improved, and the linear active disturbance rejection controller is added in an arc voltage loop, so that the robustness of the welding system of the embedded crawling robot is improved, and the welding seam forming quality is improved.

Description

Embedded type centralized controller device of welding system of crawling robot
Technical Field
The invention relates to the technical field of intelligent welding control, in particular to a centralized controller device of a welding system of a crawling robot based on an embedded type.
Background
In the field of welding of crawling robots, multiple devices such as a welding power supply, a crawling robot, a wire feeder, a touch screen and the like are often required to be controlled simultaneously on site, and the problem of cooperative control of the multiple devices is solved. In the selection of the centralized controller platform, a multi-controller combination is adopted, for example, in the control of a traditional PC as an upper computer, because the traditional PC is not designed for an industrial environment, a welding environment often generates a large amount of electromagnetic noise, the reliability of the PC is influenced, and the defects of large volume and high cost exist. In addition, in the welding of a complex curved surface, the curved surface has certain unevenness, so that the distance between a welding torch and a parent metal is changed, the stability of arc voltage is influenced, and the quality of formed welding seams is influenced.
In the prior art, an ARM upper computer and a DSP lower computer are combined to form a controller, a control system for a welding robot (an embedded welding robot control system is designed to be [ J ]. the combined machine tool and an automatic processing technology, 2017(01):89-91+94.) is adopted, the ARM upper computer and the DSP lower computer are communicated by an RS232 circuit, and due to the fact that a multi-controller platform is adopted, two sets of minimum system circuits are needed, hardware circuits are complex, communication rates among different controllers are low, and the real-time performance of a welding process is difficult to meet.
Disclosure of Invention
In order to solve the existing problems, the invention provides a centralized controller device of an embedded crawling robot welding system; the centralized controller device is strong in anti-interference capability, small in size, low in cost, rich in expansion interfaces, capable of meeting the requirement of cooperative control with multiple devices in the welding occasion of the crawling robot, capable of adjusting welding parameters in real time through the centralized controller device, controlling the welding process, capable of improving working efficiency, and capable of adding a linear auto-disturbance-rejection controller in an arc voltage loop, and capable of improving robustness of an embedded crawling robot welding system.
The purpose of the invention is realized by at least one of the following technical solutions.
The integrated controller for embedded crawling robot welding system includes a processor, and a converting circuit, a power source circuit, a memory circuit, an interface circuit, a communication circuit, a digital input circuit and a digital output circuit connected separately to the processor.
Further, the processor adopts a multi-core heterogeneous chip, and comprises double A7 cores and an M4 core; the first A7 kernel and the second A7 kernel in the double A7 kernels are connected with each other through a shared bus, an embedded Linux system is operated together, and parallel operation is realized by distributing multiple threads to different A7 kernels, so that the operation speed is increased; the double A7 kernels are connected with the M4 kernel through a bus, receive processing information from the M4 kernel, and are used for processing TCP/IP communication and transceiving of a Modbus high-level protocol, communicating with a touch screen and controlling the whole welding process; the M4 kernel runs a FreeRTOS real-time system to acquire and set AD/DA data, closed-loop control of arc voltage and realization of a control algorithm are completed in the M4 kernel, AD sampling data are sent to the double A7 kernels and used for displaying the arc voltage and welding current in real time, and the double A7 kernels send arc voltage setting parameters to the M4 kernel.
Further, the conversion circuit comprises an AD conversion circuit and a DA conversion circuit, and is used for sampling the arc voltage and the welding current in real time, converting the analog quantity signal into a digital quantity, and inputting the digital quantity signal into an M4 kernel for closed-loop control and real-time display of the arc voltage;
the power supply circuit comprises a 24V-to-5V power supply circuit and a 24V-to-3.3V power supply circuit, provides stable power supply input for the centralized controller device and provides power supply for the on-chip peripherals;
the 24V-to-5V power supply circuit is connected with the processor, the storage circuit, the interface circuit and the communication circuit and provides power supply input;
the 24V to 3.3V power supply circuit is connected with the digital quantity input circuit, the digital quantity output circuit and the conversion circuit and provides power supply input.
Further, the memory circuit comprises an EMMC memory circuit and a TF-SD card memory circuit;
the EMMC storage circuit is used for storing a system mirror image of the embedded Linux system and guiding a UBoot mirror image started by the embedded Linux system, the UBoot mirror image is used for initializing a hardware peripheral when the controller is powered on, providing an environment for the operation of the embedded Linux system and finally transferring the control right to the embedded Linux system;
a root file system manufactured based on Buildrop is stored in the EMMC storage circuit and used for storing a program mirror image of an M4 kernel and storing environment variables of the centralized controller device;
the TF-SD card storage circuit is used for expanding the storage space of the centralized controller device and exporting data;
the interface circuit comprises a JTAG interface circuit and a USB interface circuit;
the JTAG interface circuit is used for firmware programming in the M4 kernel debugging stage;
the USB interface circuit is used for programming the EMMC storage circuit and updating a system image and a root file system of the embedded Linux system.
Further, the communication circuit comprises a USB serial port communication circuit, a network port circuit, an RS232 circuit and a double RS485 circuit;
the USB serial port communication circuit is connected with the processor and the upper computer and is used for outputting embedded Linux system debugging information in the upper computer and observing the running state of the embedded Linux system;
the network port circuit comprises a 100M network port circuit and a 1000M network port circuit and is used for realizing the communication between the processor and the control box of the crawling robot;
the RS232 circuit is used for realizing the communication between the processor and the touch screen;
the double RS485 circuits respectively realize the communication between the processor and the welding power supply and the wire feeder through the two RS485 circuits, and further realize the control of the processor on the starting and stopping of the welding power supply, the arc voltage, the welding current and the wire feeding speed.
Furthermore, the digital quantity input circuit adopts 24 paths of digital quantity input circuits which are respectively connected with the processor and the entity buttons of the start button, the emergency stop button and the stop button; the start button is used for starting a welding process, and the emergency stop button is used for stopping the operation of a welding power supply, a wire feeder and a crawling robot at any time in the operation process of the welding process and entering a fault state; the stop button is used for recovering to a standby state after normal welding is finished;
the digital quantity output circuit adopts a 16-path digital quantity output circuit and is used for respectively connecting the processor with the power supply indicator lamp, the working state indicator lamp and the alarm indicator lamp; the power supply indicator lamp is a power supply indicator lamp; the working state indicator lamp is turned off in the welding process, and a green lamp is displayed after welding to indicate that the welding operation is finished; the alarm indicator light is a red light which is displayed after a fault condition occurs or an emergency stop button is pressed, and the condition indicates that the operator needs to further process.
Further, the device comprises a centralized controller device, a crawling robot control box, a welding power supply, a wire feeder and a touch screen;
the centralized controller device is respectively connected with the crawling robot control box, the welding power supply, the wire feeder and the touch screen and used as a control center to control the welding process, and the centralized controller device sends a control instruction to the crawling robot control box, communicates with the wire feeder and sends a wire feeding speed setting instruction, communicates with the welding power supply to control the start and stop of the crawling robot control box, collects an arc voltage curve of the welding power supply and completes voltage closed-loop control on the welding process;
the wire feeder receives a wire feeding speed setting instruction sent by the centralized controller device and independently completes closed-loop control on the wire feeding speed;
the touch screen is used for displaying welding process data and setting welding parameters to complete processing of fault information.
Furthermore, in the centralized controller device, the processor is respectively connected with the welding power supply and the wire feeder through a double RS485 circuit; the processor is connected with the crawling robot control box through a network port circuit; the processor is connected with the touch screen through an RS232 circuit;
the touch screen is provided with virtual buttons which have the functions consistent with the functions of a starting button, an emergency stop button and a stop button on the centralized controller device respectively;
the touch screen is provided with virtual indicator lamps which have the same functions as the power indicator lamp, the working state indicator lamp and the alarm indicator lamp on the centralized controller device respectively.
Further, the centralized controller device adopts a Linear Active Disturbance Rejection Control (LADRC) technology to complete closed-loop control of the arc voltage, which specifically comprises the following steps:
first, the arc voltage set value UsThe RPMsg message channel of the double A7 kernels is sent to the M4 kernel, and the centralized controller device collects an arc voltage signal u through a conversion circuitaFeeding back into an M4 core, the M4 core being responsible for the implementation of a Linear Active Disturbance Rejection Control (LADRC) algorithm, including discrete implementations of a Linear Extended State Observer (LESO) and a proportional derivative controller (PD); wherein the input signal of the linear extended state observer has uaAnd outputting a control signal d to output three observation state values uaIs observed value z1、uaDifferentiated observed value z2Observed value z of total external disturbance3，z1And z2The signal is connected to a proportional-derivative controller (PD) which is arranged in an M4 core, and z3The signal is connected to the output side of the proportional-differential controller, and a signal u is obtained after the total external disturbance of the welding system is eliminatedbSignal ubThen the constant link of the welding system is 1/b0And (4) calculating to obtain a final control signal d, and sending the control signal d to the welding power supply through a double RS485 circuit to complete the closed-loop control of the arc voltage.
Furthermore, the welding process is completed by double A7 kernels, the centralized controller device is communicated with the crawling robot control box through a TCP/IP protocol stack and communicated with a welding power supply and a wire feeder through a Modbus protocol;
firstly, entering an initialization stage, using a double A7 kernel as a master station to poll a crawling robot control box, a welding power supply and a wire feeder, periodically sending a control command or a heartbeat packet after all devices are communicated online, simultaneously displaying the online state of the devices through a touch screen, setting a welding mode through the touch screen by an operator, setting parameters of welding walking speed, welding current, arc voltage, wire feeding speed and communication baud rate, periodically sending the control command to the crawling robot control box and the wire feeder through a virtual button corresponding to a start button on the touch screen or a start button on a centralized controller device, controlling the walking speed of the crawling robot and the wire feeder speed of the wire feeder, returning to a ready state to the centralized controller device after the crawling robot returns to a welding seam starting point, sending the start command to the welding power supply by the centralized controller device to start welding, the double A7 inner core enters a welding stage;
in the welding process, the double A7 kernels send the set value of the arc voltage to the M4 kernel, the arc voltage closed-loop control of the M4 kernel is started, the centralized controller device carries out the closed-loop control of the arc voltage according to the collected arc voltage data, and the arc voltage is automatically adjusted to be stable;
when the welding seam of the crawling robot is tracked to the terminal point and state information is returned to the centralized controller device, or a stop button of the centralized controller device or a virtual button corresponding to the stop button on the touch screen is pressed, the double A7 kernels can finish the welding state in advance when receiving a stop instruction, the double A7 kernels send the finish instruction to the welding power supply and the wire feeder through the double RS485 circuits and send the instruction to the crawling robot control box through the network port circuit, and the wire feeder is stopped from feeding wires, the welding power supply is closed and the crawling robot is stopped from moving;
when a fault occurs, fault information is displayed on the touch screen, and the welding can be continued by processing the fault information by an operator.
Compared with the prior art, the invention has the advantages that:
the embedded centralized controller device for the welding system of the crawling robot adopts heterogeneous multi-core chips, has high inter-core communication speed, strong anti-interference capability, small volume, low cost and rich expanded interfaces, and meets the requirement of cooperative control with multiple devices in the welding occasion of the crawling robot.
The embedded crawling robot welding system can adjust welding parameters in real time through the centralized controller device, controls the welding process, improves the working efficiency, and adds a linear active disturbance rejection controller in an arc voltage loop, so that the robustness of the embedded crawling robot welding system is improved, and the welding seam forming quality is improved.
Drawings
Fig. 1 is a schematic diagram of a centralized controller system of an embedded crawling robot welding system according to the present invention.
Fig. 2 is a circuit block diagram of the centralized controller device of the embedded crawling robot welding system of the present invention.
Fig. 3 is a control block diagram of the centralized controller device of the embedded crawling robot welding system of the present invention.
Fig. 4 is a touch screen interface connected with a centralized controller of the embedded crawling robot welding system.
Detailed Description
The technical solution of the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments, and all other embodiments obtained by those skilled in the art without any inventive work based on the embodiments of the present invention belong to the protection scope of the present invention.
Example (b):
an embedded centralized controller device for a welding system of a crawling robot is shown in fig. 2 and comprises a processor, and a conversion circuit, a power supply circuit, a storage circuit, an interface circuit, a communication circuit, a digital input circuit and a digital output circuit which are respectively connected with the processor.
In the embodiment, the processor adopts an STM32MP157DAA1 multi-core heterogeneous chip, the multi-core heterogeneous structure is formed based on dual cores A7800 MHz main frequency and 209MHz M4, the processor is integrated on one chip, and simultaneously runs embedded Linux and FreeRTOS which respectively run on different kernels, wherein a first A7 kernel and a second A7 kernel are mutually connected through a shared bus, an embedded Linux system is run together, multithreading is distributed to different A7 kernels to realize parallel operation, the operation speed is improved, the double A7 kernels are also connected with the M4 kernel through the bus, and processing information from the M4 kernel is received for processing TCP/IP communication and transceiving of Modbus high-level protocols, communication with a touch screen and control of the whole welding process; the M4 kernel runs a FreeRTOS real-time system to acquire and set AD/DA data, closed-loop control of arc voltage and realization of a control algorithm are completed in the M4 kernel, AD sampling data are sent to the double A7 kernels and used for displaying the arc voltage and welding current in real time, and the double A7 kernels send arc voltage setting parameters to the M4 kernel.
In this embodiment, the conversion circuit includes an AD conversion circuit and a DA conversion circuit, and is used for sampling arc voltage and welding current in real time, and converting an analog signal into a digital signal, and inputting the digital signal into an M4 kernel for closed-loop control and real-time display of the arc voltage, the AD conversion circuit is composed of two AD5644RBRMZ four-channel DAC chips and corresponding resistance-capacitance devices, and the DA conversion circuit is composed of an ADs8698IDBT eight-channel ADC sampling chip and corresponding resistance-capacitance devices.
In this embodiment, the power circuit includes a 24V to 5V power circuit and a 24V to 3.3V power circuit, and provides a stable power input for the centralized controller device and a power supply for the on-chip peripherals; the 24V-to-5V power supply circuit is connected with the processor, the storage circuit, the interface circuit and the communication circuit and provides power supply input, and specifically, an LM2596S-5BUCK power supply chip is used for reducing the 24V direct current into 5V direct current; the 24V-to-3.3V power supply circuit is connected with the digital quantity input circuit, the digital quantity output circuit and the conversion circuit and provides power supply input, and specifically, the 24V direct current is reduced to 3.3V direct current by a TLV62090RGT and LM2596S-5 power supply chip.
In this embodiment, the memory circuit includes an EMMC memory circuit and a TF-SD card memory circuit;
the EMMC storage circuit is used for storing a system mirror image of the embedded Linux system and guiding a UBoot mirror image started by the embedded Linux system, the EMMC chip adopts a KLM8G1GETF single-chip 8G storage chip, the UBoot mirror image is mainly used for initializing a hardware peripheral when the controller is powered on, providing an environment for the operation of the embedded Linux system, and finally transferring the control right to the embedded Linux system; the EMMC storage circuit is also stored with a root file system manufactured based on Buildrop and used for storing program mirror images of an M4 kernel and storing environment variables of a centralized controller device
The TF-SD card storage circuit is used for expanding the storage space of the centralized controller device and exporting data.
In this embodiment, the interface circuit includes a JTAG interface circuit and a USB interface circuit;
the JTAG interface circuit is used for firmware programming in the M4 kernel debugging stage;
the USB interface circuit is used for programming the EMMC storage circuit and updating a system image and a root file system of the embedded Linux real-time system.
In this embodiment, the communication circuit includes a USB serial port communication circuit, a network port circuit, an RS232 circuit, and a dual RS485 circuit;
the USB serial port communication circuit is connected with the processor and the upper computer and used for outputting embedded Linux system debugging information in the upper computer and observing the running state of the embedded Linux system, and the specific circuit adopts a CH340C level conversion chip to complete the USB serial port function;
the network port circuit comprises a 100M network port circuit and a 1000M network port circuit and is used for realizing the communication between the processor and the control box of the crawling robot, wherein the 1000M network port circuit is formed by adopting an RTL8211F PHY chip and an HR911131A interface, and the 100M network port circuit is formed by adopting an LAN9500AI-ABZJ chip and an HR911105A interface;
the RS232 circuit is used for realizing communication between the processor and the touch screen, and the main circuit is completed by adopting an MAX3232ESE chip;
the double RS485 circuits respectively realize the communication between the processor and the welding power supply and the wire feeder through the two RS485 circuits, so as to realize the control of the processor on the start and stop of the welding power supply, the arc voltage, the welding current and the wire feeding speed; in this embodiment, the dual RS485 circuit mainly uses two MAX3485EESA chips to form the dual RS485 circuit.
In this embodiment, the digital input circuit adopts 24 digital input circuits, which are respectively connected with the processor and the physical buttons of the start button, the emergency stop button and the stop button; the start button is used for starting a welding process, and the emergency stop button is used for stopping the operation of a welding power supply, a wire feeder and a crawling robot at any time in the operation process of the welding process and entering a fault state; the stop button is used for recovering to a standby state after normal welding is finished; the 24-path digital quantity input circuit is mainly formed by 6 TLP521-4 optical coupling isolation chips.
The digital quantity output circuit adopts a 16-path digital quantity output circuit and is used for respectively connecting the processor with the power supply indicator lamp, the working state indicator lamp and the alarm indicator lamp; the power supply indicator lamp is a 24V power supply indicator lamp, the working state indicator lamp is turned off in the welding process, and a green lamp is displayed after welding to indicate that the welding operation is finished; the alarm indicator light is a red light which is displayed after a fault condition occurs or an emergency stop button is pressed, and the condition indicates that the further processing of an operator is needed; the 16-path digital quantity output circuit is mainly formed by 4 TLP521-4 optical coupling isolation chips and corresponding MJD122 triodes.
In this embodiment, the centralized controller device plays a role of master station control, and polls each slave station at a frequency of 20ms to perform data interaction between the master station and the slave station.
In this embodiment, an embedded crawling robot welding system, as shown in fig. 1, includes a centralized controller device 1, a crawling robot control box 6, a crawling robot 5, an industrial camera 4, a welding torch 7, a welding power supply 2, a wire feeder 3, and a touch screen 8;
the centralized controller device 1 is respectively connected with the crawling robot control box 6, the welding power supply 2, the wire feeder 3 and the touch screen 8, is used as a control center to control the welding process, and comprises the steps of sending a control instruction to the crawling robot control box 6, communicating with the wire feeder 3 and sending a wire feeding speed setting instruction, communicating with the welding power supply 2 to control the start and stop of the welding power supply, collecting an arc voltage curve of the welding power supply 2, and finishing voltage closed-loop control on the welding process;
the wire feeder 3 receives a wire feeding speed setting instruction sent by the centralized controller device 1 and independently completes closed-loop control on the wire feeding speed;
the crawling robot control box 6 can independently control the crawling robot 5, the industrial camera 4 and the welding torch 7, and simultaneously receives commands of the centralized controller device 1 to advance, retreat, turn left and turn right and set walking speed, the industrial camera 4 is connected with and controlled by the crawling robot control box 6 and is responsible for identifying and tracking a welding seam in a welding process, the welding torch 7 is connected with the welding power supply 2, and the crawling robot control box 6 controls a welding swing angle of the welding torch 7;
the touch screen 8 is used for displaying welding process data and setting welding parameters to complete processing of fault information.
In the embodiment, in the centralized controller device 1, the processor is respectively connected with the welding power supply 2 and the wire feeder 3 through the double RS485 circuits; the processor is connected with the crawling robot control box 6 through a network port circuit; the processor is connected with the touch screen 8 through an RS232 circuit.
The touch screen 8 is provided with virtual buttons which have the same functions as the start button, the emergency stop button and the stop button on the centralized controller device 1;
the touch screen 8 is provided with virtual indicator lights which have the same functions as the power indicator light, the working state indicator light and the alarm indicator light on the centralized controller device 1.
In this embodiment, the centralized controller apparatus 1 completes closed-loop control of the arc voltage by using a Linear Active Disturbance Rejection Control (LADRC) technology, as shown in fig. 3, specifically as follows:
first, the arc voltage set value UsThe RPMsg message channel of the double A7 kernels is sent to the M4 kernel, and the centralized controller device 1 collects an arc voltage signal u through a conversion circuitaFeeding back into an M4 core, the M4 core being responsible for LADRC algorithm implementation, including discrete implementations of a Linear Extended State Observer (LESO) and a proportional-derivative controller (PD); wherein the input signal of the linear extended state observer has uaAnd outputting a control signal d to output three observation state values uaIs observed value z1、uaDifferentiated observed value z2Observed value z of total external disturbance3，z1And z2The signal is connected to a proportional-derivative controller (PD) which is arranged in an M4 core, and z3The signal is connected to the output side of the proportional-differential controller, and a signal u is obtained after the total external disturbance of the welding system is eliminatedbSignal ubThen the constant link of the welding system is 1/b0Calculating to obtain a final control signal d, and sending the control signal d through a double RS485 circuitAnd (5) providing a welding power supply to complete the closed-loop control of the arc voltage.
Further, the welding process is completed by double A7 kernels, the centralized controller device 1 communicates with the crawling robot control box 6 through a TCP/IP protocol stack and communicates with the welding power supply 2 and the wire feeder 3 through a Modbus protocol;
firstly, entering an initialization stage, polling the crawling robot control box 6, the welding power supply 2 and the wire feeder 3 by using double A7 kernels as a master station, sending a control command or a heartbeat packet by using a 20ms period after all devices are communicated online, simultaneously displaying the online state of the devices through a touch screen, setting a welding mode by an operator through the touch screen 8, setting parameters of welding walking speed, welding current, arc voltage, wire feeding speed and communication baud rate, periodically sending the control command to the crawling robot control box 6 and the wire feeder 3 by using a virtual button corresponding to a start button on the touch screen 8 or a start button on the centralized controller device 1 through the double A7 kernels, controlling the walking speed of the crawling robot 5 and the wire feeding speed of the wire feeder, returning to a ready state after the crawling robot 5 returns to a welding seam starting point, sending the start command to the welding power supply 2 by the centralized controller device 1 to start welding, the double A7 inner core enters a welding stage;
in the welding process, the double A7 kernels send the set value of the arc voltage to the M4 kernel, the arc voltage closed-loop control of the M4 kernel is started, the centralized controller device 1 carries out the closed-loop control of the arc voltage according to the collected arc voltage data, and the arc voltage is automatically adjusted to be stable;
when the welding seam of the crawling robot 5 is tracked to the terminal point and state information is returned to the centralized controller device 1, or a stop button of the centralized controller device 1 or a virtual button corresponding to the stop button on the touch screen 8 is pressed, the double A7 kernel can finish the welding state in advance when receiving a stop instruction, the double A7 kernel sends a finish instruction to the welding power supply 2, the crawling robot control box 6 and the wire feeder 3 through a double RS485 circuit, and the wire feeder 3 stops feeding wires, the welding power supply 2 is closed and the crawling robot 5 stops moving;
when a fault occurs, fault information is displayed on the touch screen 8, and the operator is required to perform treatment to continue welding.
As shown in fig. 4, in this embodiment, the interface of the touch screen 8 is provided with a control module of the welding power supply 2, a motion control module of the crawling robot 5, a parameter setting module of the welding system, an arc voltage and current display module of real-time welding, and a start-stop control touch button of the welding process, so as to control the welding process.

Claims (10)

1. The centralized controller device of the embedded crawling robot welding system is characterized by comprising a processor, and a conversion circuit, a power supply circuit, a storage circuit, an interface circuit, a communication circuit, a digital quantity input circuit and a digital quantity output circuit which are respectively connected with the processor.
2. The centralized controller device of an embedded crawling robot welding system according to claim 1, wherein the processor is a multi-core heterogeneous chip comprising dual a7 cores and M4 cores; the first A7 kernel and the second A7 kernel in the double A7 kernels are connected with each other through a shared bus, an embedded Linux system is operated together, and parallel operation is realized by distributing multiple threads to different A7 kernels, so that the operation speed is increased; the double A7 kernels are connected with the M4 kernel through a bus, receive processing information from the M4 kernel, and are used for processing TCP/IP communication and transceiving of a Modbus high-level protocol, communicating with a touch screen and controlling the whole welding process; the M4 kernel runs a FreeRTOS real-time system to acquire and set AD/DA data, closed-loop control of arc voltage and realization of a control algorithm are completed in the M4 kernel, AD sampling data are sent to the double A7 kernels and used for displaying the arc voltage and welding current in real time, and the double A7 kernels send arc voltage setting parameters to the M4 kernel.
3. The centralized controller device of an embedded crawling robot welding system of claim 2, wherein the conversion circuit comprises an AD conversion circuit and a DA conversion circuit, which are used to sample the arc voltage and the welding current in real time and convert the analog signal into digital signal to be input into M4 kernel for closed-loop control and real-time display of the arc voltage;
the power supply circuit comprises a 24V-to-5V power supply circuit and a 24V-to-3.3V power supply circuit, provides stable power supply input for the centralized controller device and provides power supply for the on-chip peripherals;
the 24V-to-5V power supply circuit is connected with the processor, the storage circuit, the interface circuit and the communication circuit and provides power supply input;
the 24V to 3.3V power supply circuit is connected with the digital quantity input circuit, the digital quantity output circuit and the conversion circuit and provides power supply input.
4. The centralized controller device of an embedded crawling robot welding system according to claim 2, wherein the memory circuit comprises an EMMC memory circuit and a TF-SD card memory circuit;
the EMMC storage circuit is used for storing a system mirror image of the embedded Linux system and guiding a UBoot mirror image started by the embedded Linux system, the UBoot mirror image is used for initializing a hardware peripheral when the controller is powered on, providing an environment for the operation of the embedded Linux system and finally transferring the control right to the embedded Linux system;
a root file system manufactured based on Buildrop is stored in the EMMC storage circuit and used for storing a program mirror image of an M4 kernel and storing environment variables of the centralized controller device;
the TF-SD card storage circuit is used for expanding the storage space of the centralized controller device and exporting data;
the interface circuit comprises a JTAG interface circuit and a USB interface circuit;
the JTAG interface circuit is used for firmware programming in the M4 kernel debugging stage;
the USB interface circuit is used for programming the EMMC storage circuit and updating a system image and a root file system of the embedded Linux system.
5. The centralized controller device of an embedded crawling robot welding system of claim 2, wherein the communication circuit comprises a USB serial port communication circuit, a network port circuit, an RS232 circuit and a dual RS485 circuit;
the USB serial port communication circuit is connected with the processor and the upper computer and is used for outputting embedded Linux system debugging information in the upper computer and observing the running state of the embedded Linux system;
the network port circuit comprises a 100M network port circuit and a 1000M network port circuit and is used for realizing the communication between the processor and the control box of the crawling robot;
the RS232 circuit is used for realizing the communication between the processor and the touch screen;
the double RS485 circuits respectively realize the communication between the processor and the welding power supply and the wire feeder through the two RS485 circuits, and further realize the control of the processor on the starting and stopping of the welding power supply, the arc voltage, the welding current and the wire feeding speed.
6. The centralized controller device of an embedded crawling robot welding system according to claim 2, wherein the digital input circuit is 24 digital input circuits, and the digital input circuits are respectively connected with the processor and the physical buttons of the start button, the emergency stop button and the stop button; the start button is used for starting a welding process, and the emergency stop button is used for stopping the operation of a welding power supply, a wire feeder and a crawling robot at any time in the operation process of the welding process and entering a fault state; the stop button is used for recovering to a standby state after normal welding is finished;
the digital quantity output circuit adopts a 16-path digital quantity output circuit and is used for respectively connecting the processor with the power supply indicator lamp, the working state indicator lamp and the alarm indicator lamp; the power supply indicator lamp is a power supply indicator lamp; the working state indicator lamp is turned off in the welding process, and a green lamp is displayed after welding to indicate that the welding operation is finished; the alarm indicator light is a red light which is displayed after a fault condition occurs or an emergency stop button is pressed, and the condition indicates that the operator needs to further process.
7. An embedded crawling robot welding system is characterized by comprising a centralized controller device, a crawling robot control box, a welding power supply, a wire feeder and a touch screen;
the centralized controller device is respectively connected with the crawling robot control box, the welding power supply, the wire feeder and the touch screen and used as a control center to control the welding process, and the centralized controller device sends a control instruction to the crawling robot control box, communicates with the wire feeder and sends a wire feeding speed setting instruction, communicates with the welding power supply to control the start and stop of the crawling robot control box, collects an arc voltage curve of the welding power supply and completes voltage closed-loop control on the welding process;
the wire feeder receives a wire feeding speed setting instruction sent by the centralized controller device and independently completes closed-loop control on the wire feeding speed;
the touch screen is used for displaying welding process data and setting welding parameters to complete processing of fault information.
8. The embedded crawling robot welding system of claim 7, wherein the centralized controller device is connected to the welding power supply and the wire feeder via two RS485 circuits; the processor is connected with the crawling robot control box through a network port circuit; the processor is connected with the touch screen through an RS232 circuit;
the touch screen is provided with virtual buttons which have the functions consistent with the functions of a starting button, an emergency stop button and a stop button on the centralized controller device respectively;
the touch screen is provided with virtual indicator lamps which have the same functions as the power indicator lamp, the working state indicator lamp and the alarm indicator lamp on the centralized controller device respectively.
9. The welding system of claim 7, wherein the centralized controller means performs closed loop control of the arc voltage using a Linear Active Disturbance Rejection Control (LADRC) technique, as follows:
first, the arc voltage set value UsThe RPMsg message channel of the double A7 kernels is sent to the M4 kernel, and the centralized controller device collects an arc voltage signal u through a conversion circuitaFeeding back into an M4 core, the M4 core being responsible for the implementation of a Linear Active Disturbance Rejection Control (LADRC) algorithm, including discrete implementations of a Linear Extended State Observer (LESO) and a proportional derivative controller (PD); wherein the input signal of the linear extended state observer has uaAnd outputting a control signal d to output three observation state values uaIs observed value z1、uaDifferentiated observed value z2Observed value z of total external disturbance3，z1And z2The signal is connected to a proportional-derivative controller (PD) which is arranged in an M4 core, and z3The signal is connected to the output side of the proportional-differential controller, and a signal u is obtained after the total external disturbance of the welding system is eliminatedbSignal ubThen the constant link of the welding system is 1/b0And (4) calculating to obtain a final control signal d, and sending the control signal d to the welding power supply through a double RS485 circuit to complete the closed-loop control of the arc voltage.
10. The embedded crawling robot welding system of claim 8, wherein the welding process is completed by dual a7 kernels, the centralized controller device communicates with the crawling robot control box through TCP/IP protocol stack, and communicates with the welding power supply and the wire feeder through Modbus protocol;
firstly, entering an initialization stage, using a double A7 kernel as a master station to poll a crawling robot control box, a welding power supply and a wire feeder, periodically sending a control command or a heartbeat packet after all devices are communicated online, simultaneously displaying the online state of the devices through a touch screen, setting a welding mode through the touch screen by an operator, setting parameters of welding walking speed, welding current, arc voltage, wire feeding speed and communication baud rate, periodically sending the control command to the crawling robot control box and the wire feeder through a virtual button corresponding to a start button on the touch screen or a start button on a centralized controller device, controlling the walking speed of the crawling robot and the wire feeder speed of the wire feeder, returning to a ready state to the centralized controller device after the crawling robot returns to a welding seam starting point, sending the start command to the welding power supply by the centralized controller device to start welding, the double A7 inner core enters a welding stage;
in the welding process, the double A7 kernels send the set value of the arc voltage to the M4 kernel, the arc voltage closed-loop control of the M4 kernel is started, the centralized controller device carries out the closed-loop control of the arc voltage according to the collected arc voltage data, and the arc voltage is automatically adjusted to be stable;
when the welding seam of the crawling robot is tracked to the terminal point and state information is returned to the centralized controller device, or a stop button of the centralized controller device or a virtual button corresponding to the stop button on the touch screen is pressed, the double A7 kernels can finish the welding state in advance when receiving a stop instruction, the double A7 kernels send the finish instruction to the welding power supply and the wire feeder through the double RS485 circuits and send the instruction to the crawling robot control box through the network port circuit, and the wire feeder is stopped from feeding wires, the welding power supply is closed and the crawling robot is stopped from moving;
when a fault occurs, fault information is displayed on the touch screen, and the welding can be continued by processing the fault information by an operator.
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CN106956061A (en) * 2017-04-25 2017-07-18 南通市慧冠智能科技有限公司 Source of welding current power output changes acts closed loop control method with arc welding robot
CN111596599A (en) * 2020-07-07 2020-08-28 中国人民解放军陆军防化学院 Embedded information fusion equipment
US20210291289A1 (en) * 2018-12-07 2021-09-23 Beijing Bo Tsing Tech Co., Ltd Crawling welding robot and method of controlling the same

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102393656A (en) * 2011-11-29 2012-03-28 北京邮电大学 Embedded multinuclear main controller of modular robot based on FPGA (Field Programmable Gata Array)
CN102601493A (en) * 2012-03-29 2012-07-25 华南理工大学 Embedded multi-device real-time control welding robot system and control method
CN106956061A (en) * 2017-04-25 2017-07-18 南通市慧冠智能科技有限公司 Source of welding current power output changes acts closed loop control method with arc welding robot
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